Adapter for contact with crimp tail

ABSTRACT

An adapter for use with an electrical contact has a forward portion adapted to be crimped to a crimp tail section of the contact. The rearward portion of the adapter is comprised of grasping means in the form of crimp tabs which are adapted to be crimped about the conductor of a lead of larger size than said crimp tail section can accommodate to mechanically and electrically connect the conductor to the adapter and hence said contact.

United States Patent [72] Inventors Maurice E. Yonngblut 301 W. Wellens Ave., Philadelphia, Pa. 19120; James R. Hardman, Apt. 4C. Helen J. Apartments 1535 Township Line Road, Willow Grove, Pa. 19090; Alexander Wontorsky, 5226 N. Sydenham St.,

Philadelphia, Pa. 19141; William Lightkep, 1276 Dahlia Road, Warminster, Pa. 18971 Appl. No. 801,672

Filed Feb. 24, 1969 Patented Mar. 2, 1971 ADAPTER FOR CONTACT WITH CRIMP TAIL 6 Claims, 5 Drawing Figs.

U.S. Cl 339/223, 3 39/2 76 Int. Cl H01r 15/12 Field of Search 339/223,

[56] References Cited UNlTED STATES PATENTS 2,623,101 12/1952 Kurland et a1. 175/315 3,221,294 11/1965 Roberts 339/276(T) 3,348,191 10/1967 Kinkaid.... 339/176 3,412,369 11/1968 Fox 339/217 Primary ExaminerErnest R. Purser Assistant Examiner-Robert A. Hafer Attorney-D. R. Pressman ABSTRACT: An adapter for use with an electrical contact has a forward portion adapted to be crimped to a crimp tail section of the contact. The rearward portion of the adapter is comprised of grasping means in the form of crimp tabs which are adapted to be crimped about the conductor of a lead of larger size than said crimp tail section can accommodate to mechanically and electrically connect the conductor to the adapter and hence said contact.

menu-mm 2m: 3,568,137

INVENTORS.

MAURICE E. YOUNGBLUT JAMES R. HARDMAN ALEXANDER WONTORSKY WILLIAM Ll ATTORNEY.

ADAPTER FOR CONTACT WITH CRIMP TAIL This invention relates generally to an adapter for use with an electrical contact, and more particularly to an adapter having a forward portion adapted to be electrically and mechanically engaged with the crimp tail section of a contact, and a rearward portion comprised of grasping means in the form of crimp tabs adapted to electrically and mechanically engage leads.

Many electrical applications require a crimp connection between a contact and stranded or solid conductors. One type of contact having crimp tail section is sold by ELCO Corporation under its trademark VARILOK, and comprises a tail section having a first grasping means in the form of crimp tabs for mechanically engaging the insulated portion of a lead, and a second grasping means in the form of crimp tabs for electrically and mechanically engaging the conductor of said lead. The details of construction of this contact are disclosed and claimed in abandoned U.S. Pat. application No. 782,100, titled ELECTRICAL CONTACT WITH CRIMP TAIL, filed Dec. 9, 1968, which is hereby incorporated by reference. The VARILOK contact makes acceptable crimp connections with both stranded and solid conductors ranging in size from AWG 18 to AWG 30; however, there are applications wherein larger gauge conductors (e.g. AWG 16) are required because of the necessity for a greater current carrying capacity. In addition, many applications required connections in which two or more leads are connected to a single contact. One specific application requires an electrical connection between the Varilok contact, and two AWG l6 conductors.

The adapter of this invention will accommodate a single lead which is too large to be received by the standard Varilok contact, or a plurality of leads which cannot be accommodated by the standard Varilok contact. The adapter of this invention comprises an electrically conductive, longitudinally extending member having attachment means at one longitudinal end for being mechanically and electrically attached to the crimp tabs of the Varilok contact, and grasping means at the opposite longitudinal end for mechanically and electrically engaging a lead. This arrangement provides electrical continuity between the conductor of a lead and the Varilok contact.

In some applications, the contacts are assembled into a connector block in a grid pattern which will require the crimp area of the adapter to be positioned into certain planes. For example, if the contacts are positioned in a grid pattern of .200 inch X .300 inch, and the maximum width of the crimp area of the adapter is between .200 inch and .300 inch, the maximum width of the adapter cannot be received in the plane of the contacts positioned on .200 inch centers, but can be received in the plane of the contacts positioned on .300 inch centers. To permit proper orientation of the crimp area of the adapter, and at the same time permit close packing of the contacts within a connector block, the crimp area of the adapter can be twisted relative to the forward portion of the adapter to orient the crimp area in a plane which will accommodate its dimensions.

The more important features of this invention have been outlined rather broadly in order that the detailed description thereof that follows may be better understood, and in order that the contribution to the art may be better appreciated. There are, of course, additional features of the invention that will be described hereinafter and which will also form the subject of the claims appended hereto. Those skilled in the art will appreciate that the conception upon which this disclosure is based will readily be utilized as a basis for designing other structures for carrying out the several purposes of this invention. It is important, therefore, that the claims to be granted herein shall be interpreted with sufficient breadth to prevent the appropriation of this invention by those skilled in the art.

Other objects of the invention will be readily appreciated as the invention becomes better understood with reference to the following detailed description when considered in connection with the accompanying drawings, wherein:

FIG. 1 is a perspective view of the contact and adapter separated from each other for purposes of clarity;

FIG. 2 is a side view of the grasping means of the adapter shown in FIG. 1;

FIG. 3 is a section taken through line 3-3 of FIG. 2 in which the crimping position of the grasping means for engaging the insulated portion of the leads is shown by dotted representa- 1.1011;

FIG. 4 is a view taken through line 4-4 of FIG. 2 in which the crimping position of the grasping means for engaging the conductors of the leads is shown by dotted representation;

FIG. 5 is a perspective view of the adapter showing the rear portion twisted relative to the forward portion.

Referring to FIG. 1, the adapter 30 of this invention is shown separated from contact a. The contact 10a is sold by ELCO Corporation under its trademark VARILOK, and is comprised of a mating section 12a and a tail sectiol7a interconnected by a body section 14a. The contact has a locking lance 50a and a pair of locking shoulders 52a which'cooperate with shoulders in an insulating housing to firmly retain the contact within such housing. The mounting of the contact within the insulating housing is clearly shown in U.S. Pat. No.

1 3,248,686, filed Mar. 16, 1965, the disclosure of which is hereby incorporated by reference..The tail secton 16a of the contact is comprised of a first grasping means 18:: consisting of a pair of generally triangular crimp tabs 20a, and a second grasping means 24a forward of said first grasping means and consisting of a pair of crimp tabs 26a. The first grasping means 18a is adapted to be crimped about the insulated portion of a lead, and the second grasping means 24a of each contact is adapted to be crimped about the conductor of the lead. The transverse dimension between crimp tabs 26a is less than the transverse dimension between crimp tabs 20a because the conductor of the lead which is received between the crimp tabs 26a is of a smaller dimension than the insulated portion of the lead which is received between crimp tabs 20a. The second crimp tabs 26a have generally planar side edges 33a, the function of which will be explained infra.

The adapter 30 of this invention-is made of a suitable electrically conductive material such as brass, copper, berillium copper, or phosphor bronze. The adapter is a generally elongated member comprising a forward attaching portion 32 and a rearward tail portion 34 interconnected by a body portion 36.

The forward attachingportion 32 of adapter 30 is comprised of first and second longitudinally extending sections, 38, 40 respectively, said second section 40 being rearward of said first section 38 and having a larger-transverse dimension than said first section. Forwardly facing shoulders 42 are formed at the junction between the first and second sections (FIG. 1). The function of shoulders 42 will be explained infra.

The rearward tail portion 34 is comprised of a first grasping means 44 consisting of a pair of crimp tabs 46 interconnected by a bridging section 52 (see FIGS. 2 and 3), and a second grasping means 48 consisting of a pair of crimp tabs 50 interconnected by a bridging section 54 (FIGS. 2 and 4). The bridging section 54 is positioned slightly above, or at a different level, from the bridging section 52 as defined by step 56 (FIG. 2). The first grasping means 44 of the adapter is adapted to be crimped about the insulated portion of a lead, or a group of leads, and the grasping means 48, which is forward of grasping means 44 is adapted to be crimped about the conductors of such leads. Each crimp tab 46 of the first grasping means 44 is comprised of an upper section having a flat surface 60. In the crimp position, flattened surfaces 60 on each tab mate with each other to provide a tight crimp seal, as is clearly shown in FIG. 3. Each crimp tab 50 of the second grasping means 48, is also provided with a flattened surface 62. The flattened surfaces 62 engage each other when the crimp tabs 50 are in crimped position as is shown by the dotted representation in FIG. 4. This arrangement provides firm mechanical and electrical engagement between the conductors of the leads and the crimp tabs 50.

In the preferred embodiment, the body portion 36, and forward attaching portion 32 of the adapter are substantially flat and coplanar, and are connected to the rearward tail portion through an incline region 56 (FIG. 2). Alternatively the incline region 56, can be positioned between the first and second longitudinally extending sections 38 and 40, respectively.

The contact 10a and the adapter 30 are assembled in the following manner. The adapter 30 is inserted into contact 10a until forwardly facing shoulders 42 on adapter 30 contact side surfaces 33a on the crimp tabs 26a of the contact. The shoulders 42 will engage side surfaces 33a because the transverse dimension of the second section 40 of the attaching portion 32 is greater than the transverse dimension between side surfaces 334 of tabs 260. After shoulders 42 engage side surfaces 33a, the crimp tabs 26a and 20a of the contact are crimped about first section 38 and second section 40 of the adapter.

The contact-adapter combination is extremely versatile, because the adapter can accommodate many different combinations of electrical conductors.

For example, the grasping means of the adapter can accommodate one or two 16 AWG conductors, two or three 20 AWG conductors, or conductors having the equivalent area in circular mils.

Also, as explained above, the adapter 30 can be twisted when space requirements necessitate positioning the grasping means in a position other than that shown in FIG. 1. For example, the adapter can be twisted in the region of second longitudinally extending section 40 to orient the tail portion 34 in a plane which is disposed at an angle of 90 to the plane of the forward attaching portion 32 (FIG. 5).

It is further understood that the adapter can be utilized with many contacts having a crimp tail section, and is not necessarily limited to use with ELCOs Varilok contact.

We claim:

1. In an electrical contact of the type comprising a forward mating section, a rearward lead grasping section, and an intermediate mounting section joining said mating section with said lead grasping section, said lead grasping section of said contact comprising relatively small crimpable means for grasping leads of a first predetermined range of sizes, an improvement comprising an adapter for enabling leads of greater than said predetermined range of sizes to be electrically and mechanically connected to said contact, said adapter comprising an elongated member having an attachment section at a forward end thereof which can be electrically and mechanically attached by said relatively small crimpable means to said grasping section of said contact and having a lead grasping section at the rear end thereof comprising relatively large crimpable means for grasping leads of a second predetermined range of sizes which includes leads of sizes greater than said any size within said first range of sizes.

2. The combination of claim 1 wherein said lead grasping means of said adapter comprises a first pair of crimp tabs of relatively large size for crimping about an insulated portion of a lead and a second pair of crimp tabs adjacent said first pair of crimp tabs and of a relatively small size for crimping about the conductor of said lead.

3. The combination of claim 1 wherein said lead grasping section of said contact comprises a first pair of crimp tabs of a relatively large size for normally crimping about an insulated portion of a lead and a second pair of crimp tabs forward of said first pair of crimp tabs and of a relatively small size for normally crimping about the conductor of said lead, and wherein said attachment section of said adapter comprises a first secton of a size which can be grasped by said relatively small pair of crimp tabs of said contact, and a second section, adjacent said first section and of a larger size then said first section, which can be grasped by said relatively large pair of crimp tabs of said contact.

4. The combination of claim 3 wherein said first and second sections of said adapter are coplanar and substantiall flatl 5. The combma ion of claim 1 wherein said a pter mcludes an intermediate section interconnecting said attachment section and said grasping section, said intennediate section comprising a substantially fiat member which has been twisted such that said lead grasping section of said adapter faces a different direction than said attachment section of said adapter.

6. The combination of claim 1 wherein said lead grasping section of said contact comprises:

a first pair of crimp tabs of a relatively large size and spacing therebetween, and joined by a f'ust bridging section, for normally crimping about the insulated portion of a lead; and

a second pair of crimp tabs, forward of said first pair of crimp tabs of a relatively small size and spacing therebetween, and joined by a second bridging section which is not coplanar with said first bridging section, for normally crimping about the conductor of said lead, and wherein said attachment section of said adapter comprises a substantially fiat elongated portion having a first section of a relatively small width for being grasped by said second pair of crimp tabs of said contact, and a second section, rearward of said first section and of a relatively large width greater than said first width, for being grasped by said first pair of crimp tabs of said contact, said second section having a first pair of shoulders adjacent said first section, said first pair of shoulders being wider than the spacing between said second pair of crimp tabs of said contact, said adapter having a portion, rearward of said second section and wider than said second section, which has a second pair of shoulders adjacent said second section, said second pair of shoulders being wider than the spacing between said first pair of crimp tabs, whereby said first and second pair of shoulders can engage the sides of said second and first pair of crimp tabs, respectively, to position said adapter accurately in said contact. 

1. In an electrical contact of the type comprising a forward mating section, a rearward lead grasping section, and an intermediate mounting Section joining said mating section with said lead grasping section, said lead grasping section of said contact comprising relatively small crimpable means for grasping leads of a first predetermined range of sizes, an improvement comprising an adapter for enabling leads of greater than said predetermined range of sizes to be electrically and mechanically connected to said contact, said adapter comprising an elongated member having an attachment section at a forward end thereof which can be electrically and mechanically attached by said relatively small crimpable means to said grasping section of said contact and having a lead grasping section at the rear end thereof comprising relatively large crimpable means for grasping leads of a second predetermined range of sizes which includes leads of sizes greater than said any size within said first range of sizes.
 2. The combination of claim 1 wherein said lead grasping means of said adapter comprises a first pair of crimp tabs of relatively large size for crimping about an insulated portion of a lead and a second pair of crimp tabs adjacent said first pair of crimp tabs and of a relatively small size for crimping about the conductor of said lead.
 3. The combination of claim 1 wherein said lead grasping section of said contact comprises a first pair of crimp tabs of a relatively large size for normally crimping about an insulated portion of a lead and a second pair of crimp tabs forward of said first pair of crimp tabs and of a relatively small size for normally crimping about the conductor of said lead, and wherein said attachment section of said adapter comprises a first secton of a size which can be grasped by said relatively small pair of crimp tabs of said contact, and a second section, adjacent said first section and of a larger size then said first section, which can be grasped by said relatively large pair of crimp tabs of said contact.
 4. The combination of claim 3 wherein said first and second sections of said adapter are coplanar and substantially flat.
 5. The combination of claim 1 wherein said adapter includes an intermediate section interconnecting said attachment section and said grasping section, said intermediate section comprising a substantially flat member which has been twisted such that said lead grasping section of said adapter faces a different direction than said attachment section of said adapter.
 6. The combination of claim 1 wherein said lead grasping section of said contact comprises: a first pair of crimp tabs of a relatively large size and spacing therebetween, and joined by a first bridging section, for normally crimping about the insulated portion of a lead; and a second pair of crimp tabs, forward of said first pair of crimp tabs of a relatively small size and spacing therebetween, and joined by a second bridging section which is not coplanar with said first bridging section, for normally crimping about the conductor of said lead, and wherein said attachment section of said adapter comprises a substantially flat elongated portion having a first section of a relatively small width for being grasped by said second pair of crimp tabs of said contact, and a second section, rearward of said first section and of a relatively large width greater than said first width, for being grasped by said first pair of crimp tabs of said contact, said second section having a first pair of shoulders adjacent said first section, said first pair of shoulders being wider than the spacing between said second pair of crimp tabs of said contact, said adapter having a portion, rearward of said second section and wider than said second section, which has a second pair of shoulders adjacent said second section, said second pair of shoulders being wider than the spacing between said first pair of crimp tabs, whereby said first and second pair of shoulders can engage the sides of said second and first pair of crimp tabs, respectively, to position said adapter accurately in said contact. 